Corsa Performance 21121 Installation guide

Brand
Corsa Performance
Model
21121
Type
Installation guide

This manual is also suitable for

140 Blaze Industrial Pkwy, Berea, OH 44017
Toll Free: 1.800.486.0999
Fax: 440.891.1868
www.corsaperformance.com
IMPORTANT!
WARRANTY AND INSTALLATION
INSTRUCTIONS
Please Forward All Information to End Consumer
Be sure to review the enclosed instructions prior to beginning the installation process. If you have any
questions about the enclosed parts or instructions, or if you encounter a problem during installation:
CALL TECHNICAL SUPPORT: 440.891.0999 or 800.486.0999
COLOR INSTRUCTIONS ARE AVAILABLE BY PART NUMBER ON:
corsaperformance.com
NEVER work on a hot exhaust system.
Allow time for the vehicle to cool.
Always wear eye protection
when working under a vehicle.
INSTALL DIFFICULTY
Recommended Tools & Supplies
• 13mm Socket & Ratchet or Wrench
• 15mm Socket & Ratchet or Wrench
• 18mm Socket & Ratchet or Wrench
TO ACTIVATE YOUR WARRANTY, GO TO:
corsaperformance.com/warranty
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
2
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Please take time to read and understand these installation instructions.
CORSA recommends that the installation of this system be performed by a qualified service center or
professional installer who has the necessary equipment, tools, and experienced personnel. However, if you
decide to perform this installation yourself, the use of an additional person may be required.
WARNING: Never work on a hot exhaust system. Allow time for the vehicle to cool.
Always wear eye protection when working under a vehicle.
This warranty does not extend to damaged or defect in the finish of a product or to any product, that in the
opinion of CORSA Performance, has been misused, damaged by accident or negligence, altered, or modified
in any way, faulty installation or installed contrary to CORSA installation instructions, or repaired by an
unauthorized service facility. Full warranty available on www.corsaperformance.com
Please confirm that all parts are present according to the bill of materials before beginning the installation.
If something is missing, call CORSA Tech Support at 440.891.099 or Toll Free: 1.800.486.0999
Bill of Materials
1. JKU Head Pipe (28JK4019)
2. JLU Head Pipe (28JL4040)
3. JKU/JLU Muffler (28JK2001)
4. Tip Assembly (28JK3002 - Polish) (28JK3002BLK – Black)
5. JKU Mid-Pipe (28JK4020)
6. JLU Mid-Pipe (28JL4041)
7. JKU Single Tail Pipe (28JK4021)
8. JLU Single Tail Pipe (28JL4023)
9. JKU Wye and Driver Tail Pipe (28JK4009)
10. JLU Wye and Driver Tail Pipe (28JL4029)
11. JKU Passenger Tail Pipe (28JK4026)
12. JLU Passenger Tail Pipe (28JL4043)
13. JKU only 2½in Clamp (20EX7000)
14. Single Tail Pipe Hardware Pack (20MU7020)
15. Dual Tip Hardware Kit (17CH7008)
3
1
5
2
3
4
4
6
7
8
9
10
11
12
13
14
14
15
15
JKU
JLU
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
3
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Removal Instructions
Factory Exhaust
1. Locate the Clamp on the inlet of the Factory
Muffler. With a 15mm Socket & Ratchet or
Wrench, loosen the clamp. (JLU Shown)
JKU Driver’s Side
JKU Passenger Side
JLU (Driver side shown)
2. For JKU only: Locate the Rear Hanger Grommets for the Muffler. Using Grommet Pulling Pliers or similar,
remove Factory Hangers from the Grommets.
For JLU only: Locate the Rear Hanger Mounts for the Muffler. Using a 13mm Socket & Ratchet or
Wrench, remove 2 Bolts from each Mount. Keep the 4 Bolts in a safe place. They will be reinstalled on
Installation Step 1.
The use of a soap and water solution will aid in the removal of the hangers from the factory grommets.
3. Remove the Factory Muffler from the vehicle by wiggling and twisting it back and forth while pulling.
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
4
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Removal Instructions
Factory Exhaust
4. For JLU only: After removing the Factory Muffler from the vehicle, use Grommet Pulling Pliers or similar,
to remove the Factory Hanger Mounts from the Muffler. Note the location and orientation of the mounts.
Keep the Mounts in a safe place. They will be reinstalled on the same side during Installation Step 1.
The use of a soap and water solution will aid in the removal of the hangers from the factory grommets.
5. For JLU only: Use a 13mm Socket & Ratchet or
Wrench to remove the Nuts that attach the
Transfer Case Skid Plate to the Fuel Tank Skid
Plate. Keep the Nuts in a safe place. They will be
reinstalled on Installation Step 17.
6. Using a 18mm Socket & Ratchet or Wrench,
remove the 4 Bolts holding the Transfer Case Skid
Plate to the Vehicle Frame. Keep the Bolts in a
safe place. They will be reinstalled on Installation
Step 17.
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
5
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Removal Instructions
Factory Exhaust
JKU
JLU
7. Using a 15mm Socket & Ratchet or Wrench (JKU) or 13mm Socket & Ratchet or Wrench (JLU), loosen
the Clamp on the Head Pipe. The JLU will reuse the Stock Spherical Clamp, so keep it in a safe place to
be reinstalled on Installation Step 2. The JKU will use the supplied 2.50in Clamp.
JKU Front Hanger
JKU Mid Hanger
JLU Mid Hanger
8. Using Grommet Pulling Pliers or similar, remove the Mid Exhaust Hanger from the Grommet. Rest the
Factory Exhaust Pipe on the Axle Tube.
For JKU only: Using Grommet Pulling Pliers or similar, remove the Front Exhaust Hanger from the
Grommet.
The use of a soap and water solution will aid in the removal of the hangers from the factory grommets.
9. Next, pull back on the Factory Exhaust to release the connection on the Head Pipe. Then, remove the
exhaust by pushing the Factory Exhaust forward and out from under the Vehicle. A second person may be
needed to assist with this step.
This concludes the removal of the factory exhaust.
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
6
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
WARNING!!
DO NOT SKIP THIS STEP
WARNING!!
Apply the supplied Anti-Seize Lubricant to ONLY the threads
of the clamps and flange bolts. Failure to follow this
procedure can cause nuts to seize on clamps and potentially
destroy the threads.
After applying anti-seize lubricant, be sure to thoroughly
clean your hands. The Anti-Seize lubricant will tarnish
stainless steel.
All clamps should be tightened using a properly calibrated
Torque Wrench. Using an impact gun will damage the clamp
and reduce its ability to effectively seal the joint. It may also
cause the joint to separate, thereby causing damage to your
exhaust system and to your vehicle.
Before installing, make a line 1⅝in from the end of non-expanded side of the pipes and muffler.
This is CORSA’s nominal overlap for 2¾in tubing. This will help during final adjustment. Do not
be alarmed if the overlap varies slightly when the installation is complete. Any differences are
caused by manufacturing variances from vehicle to vehicle and exhaust to exhaust.
Install Instruction
CORSA Exhaust
Driver Side
Passenger Side
1. For JKU only: Insert the Hanger on the Head
Pipe into the Grommet.
2. For JLU only: Locate the Rear Hanger Mounts
from Removal Step 4. Reinstall them on the same
side as the Factory Exhaust, with the Hooks facing
the Rear of the Vehicle. Tighten the 4 bolts to
Factory torque values.
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
7
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Install Instruction
CORSA Exhaust
3. For JLU only: Locate Spherical Clamp on the Factory Head Pipe. Using a small Flat Head Screwdriver,
pry the Locking Tab up to release the Spherical Clamp from the Factory Head Pipe. Install the Spherical
Clamp onto the Head Pipe. Rotate the Spherical Clamp so the Locking Feature is pointing forward.
JKU
JLU
4. For JKU only: Slide the supplied 2.5in Clamp
over the Head Pipe and then slide the Head Pipe
over the Factory Exhaust Pipe.
SNUG the Clamp with a 15mm Socket & Ratchet
or Wrench.
DO NOT FULLY TIGHTEN at this time!
5. For JLU only: Slide the Head Pipe with pre-
installed Factory Shperical Clamp over the
Spherical Connection on the Factory Exhaust
Pipe. SNUG the Clamp with a 13mm Socket &
Ratchet or Wrench.
DO NOT FULLY TIGHTEN at this time!
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
8
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Install Instruction
CORSA Exhaust
6. Insert the Hanger on the Mid-Pipe in the Grommet.
Allow the front of the Mid-Pipe to rotate down so
the back rests on the Heat Shield or Cabin floor.
(JLU shown)
7. Slide a supplied 2.75in Clamp over the Head Pipe.
Then slide the Expanded side of the Muffler over
the Head Pipe. A second person may be needed
to hold Muffler in place.
8. Slide a supplied 2.75in Clamp over the Mid-Pipe.
Then rotate the CORSA Mid-Pipe up, while
rotating the Muffler & Head Pipe down. Slide the
Expanded end of the Mid-Pipe over the outlet of
the Muffler. Then lift all three parts until the
exhaust is close to level.
9. While the Mid-Pipe/Muffler/Head Pipe are being
held close to level, SNUG both Clamps with a
15mm Socket & Ratchet or Wrench. (JKU shown)
A second person may be needed to hold Exhaust
in place while the other snugs the clamps.
DO NOT FULLY TIGHTEN at this time!
For Kits 21121 (JKU No Tips) and 21123 (JLU No Tips), follow Steps 9-11.
For Kits 21122 (JKU Dual Tips) and 21124 (JLU Dual Tips), skip ahead to Step 12
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
9
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Install Instruction
CORSA Exhaust
(For Steps 9 - 11, a JLU is shown. The JKU follows the same procedure)
10. Insert the Hanger on the Tail Pipe in the Grommet.
11. Slide a supplied 2.75in Clamp over the Tail Pipe.
Next rotate the Tail Pipe up and the Mid-Pipe
down and slide the Expanded end of the Tail Pipe
over the Mid-Pipe. SNUG the Clamp with a 15mm
Socket & Ratchet or Wrench.
DO NOT FULLY TIGHTEN at this time!
12. Verify your Tail Pipe is positioned similar to the
photo.
Starting at the front, verify the Hanger sections in
the Gromments and the Muffler are close to level
and all connections are straight. Finally, starting at
the Front Clamp, using a torque wrench, tighten all
clamps to 45ft-lbs. A second person may be
needed to hold the components in the correct
position while the clamps are being torqued. Skip
ahead to Step 17 for the final instructions before
starting the vehicle.
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
10
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Install Instruction
CORSA Exhaust
(For Steps 12-14, a JLU is shown. The JKU follows the same procedure)
13. Insert the Hanger on the Driver side Tail and Wye
Pipe in the Grommet. Next, slide a supplied 2.75in
Clamp over the Tail Pipe. Then, rotate the Tail
Pipe up and the Mid-Pipe down while sliding the
Expanded end of the Tail Pipe over the Mid-Pipe.
SNUG the Clamp with a 15mm Socket & Ratchet
or Wrench.
DO NOT FULLY TIGHTEN at this time!
14. Insert the Hanger on the Passenger side Tail Pipe
in the Grommet. Then, slide a supplied 2.75in
Clamp over the Passenger side Tail Pipe. Next,
slide the Expanded end of the Tail Pipe over the
Wye Pipe.
SNUG the Clamp with a 15mm Socket & Ratchet
or Wrench.
DO NOT FULLY TIGHTEN at this time!
15. Starting at the front, verify the Hanger sections in the Gromments and the Muffler are close to level, and
all connections are striaght. Finally, starting at the Front Clamp, using a torque wrench, tighten all clamps
to 45ft-lbs. A second person may be needed to hold the components in the correct position while the
clamps are being torqued.
Continued on Next Page…
INS5421
140 Blaze Industrial Parkway, Berea, OH 44017
P: 440.891.0999
F: 440.891.1868
11
09/11/2020
[email protected]
www.corsaperformance.com
2007-2018 Jeep Wrangler JKU Kit: 21121, 21122, 21122BLK
2018+ Jeep Wrangler JLU Kit: 21123, 21124, 21124BLK
Install Instruction
CORSA Exhaust
(For Steps 15-16, a JKU is shown. The JLU follows the same procedure)
16. Slide a supplied 2.75in Clamp over each Tip
assembly and then slide the Expanded ends of the
Tip assemblies over the Tail Pipes, with the
CORSA etch on top. SNUG the Clamps with a
15mm Socket & Ratchet or Wrench.
17. Verify the Tips are straight across and even.
There should be approxiamtly ¾in between the top
of the Tips and the Bumper. To adjust, you may
need to loosen the Tail Pipe Clamps from Steps
12 and 13. Once satisfied with the alignment, use
a torque wrench, tighten the clamps on the Tail
Pipes first (if needed) and then the Tips to 45ft-lbs.
A second person may be needed to hold the
components in the correct position while the
clamps are being torqued.
18. After the exhaust is properly torqued, reinstall the Transfer Case Skid Plate by reversing Removal Steps 5
and 6. Begin by starting all the bolts and lightly snug them. For the JLU, start with the 4 bolts, then the 2
nuts. Lastly, using a Torque Wrench, tighten the hardware to Factory torque settings.
This concludes the installation of the CORSA Exhaust.
Before Road Testing
1. Start engine, leaving the transmission in park and/or securing the parking brake.
2. Make sure to look and listen for any unusual noises. Repair problems if needed.
3. Immediately following the installation of your exhaust system, you may experience a trace of smoke after
initial start-up. Do not be alarmed. The smoke is caused by the burning of a small amount of forming oil
residue used in the manufacturing process.
4. It is strongly suggested that the alignment of the components and all clamps be checked and re-torqued
after road testing the vehicle and once the system has fully cooled.
5. During cold weather start-ups, you may experience an exhaust sound that is deeper and louder in tone
than usual. This is temporary and will diminish to normal levels once your engine has reached its normal
operating temperature.
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Corsa Performance 21121 Installation guide

Brand
Corsa Performance
Model
21121
Type
Installation guide
This manual is also suitable for
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